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Building The 1920s 'New Shay' - In 3/4" Scale
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 Posted: Wed Feb 17th, 2021 04:42 am
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Reg H
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As promised, a new tool acquisition suggestion.

For many years I viewed the hack saw as a pretty much useless tool. 
Every time I used the one I had it was a frustrating experience.

Until, while working as a mechanic in a tractor repair shop,
I had the opportunity to use a Snap On hack saw.  

What a difference. 

But funds were tight and I avoided the tool trucks. 
But I definitely wanted a better hack saw in my tool box.





Neither of these two saws look like much.  But they are both excellent saws. 
My favorite is the Orion.  Both saws were picked up at garage sales. 
I don't think I paid more than $2.00 for either one of them.

A must have for a machine shop. 
Pretty useful for lots of other things as well.

When looking for a saw, look for rigidity. 
The few cheap saws I had were not stiff enough.  

Reg




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 Posted: Tue Mar 23rd, 2021 05:24 pm
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Reg H
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In amongst the remodel madness,
I have managed to squeeze in some shop time.





This is the rear end sill. 
Next step is the poling pockets.  

I missed the poling pockets on the front end sill,
so I will be making four.  

Reg




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 Posted: Thu Mar 25th, 2021 12:55 am
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Reg H
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Fortunately, the contractors are still doing their thing,
so the only thing I can do is putter in the shop. 
Shucks.

The effort recently has been the poling pockets. 
Small, but they would be missed if they weren't there. 
So.....

How to begin?  
Here is the "pocket" part of the pocket,
to be silver soldered to the pocket base.





These parts are formed by turning a piece of brass dowel,
and drilling out the center, and then cutting at an angle.

Here is the set up for doing the cutting with the slitting saw in the vertical mill.





And an enlarged view:





And the whole collection silver soldered to their bases:





Yes, there are quite small.

Finally mounted on the end sill.





The remaining two will go on the front end sill.  

Coming along.

Reg




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 Posted: Thu Apr 8th, 2021 10:40 pm
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Si.
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Hi Reg  :wave:

I'm convinced already, that you're a TOTAL pro. in the machine shop !  :brill:

The Shay frame & great looking endbeams, are really nicely made parts.  :thumb:

Couldn't agree more with you about the humble center-punch !  :old dude:

I have a couple of 'em, my trusty 'Eclipse' being top dawg !!

End mushroomed over, like crazy ... & point looks like NEW.


That mooodern 'laser-thing' looked like a loada $4!7 to me ...  :td:

... but yer know how polite I am !  ;)

Is it landfill yet ?  :P


:java::moose: :dt: 


Si.




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 Posted: Sat Apr 17th, 2021 01:46 am
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Reg H
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Si:

I haven't the heart,
to relegate the laser center finder to the trash heap. 
It may yet have a use. 

Which is, of course, the attitude that has blessed me,
with draws full of useless stuff.

My "power" center punch is an Eclipse, I believe. 
Anyway, it is British made and is an excellent tool.  


Everything has been on hold,
while working on the remodel work in our living room and den. 
But I will return to all activities once those are complete.


At the moment, we are on vacation...in Ely, Nevada. 
We are here to do the Nevada Northern This is BIG country. 
Big mountains, but wide open scenery. 

When the sign says "Exit 173, 2 miles",
and you can see it, not the sign, the exit, it is pretty amazing. 
Even taking two days, it is a very long drive from Shelton, WA.  


I will have some photos to post of the Nevada Northern,
once I get home and can fiddle with them.

Reg




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 Posted: Sat Apr 17th, 2021 11:01 pm
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Reg H
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I am posting some photos from my trip to Ely, Nevada,

in the Freerails 'Proto-Photos' Forum.


Reg





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 Posted: Sat Apr 24th, 2021 02:03 pm
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Si.
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" Anyway, it is British made and is an excellent tool "


Hi Reg  :wave:


I have the 'Eclipse' Auto Centre Punch, from Sheffield, as well !  :thumb:

I was admiring yours !  :P


:java: :cool:  :dt:


Si.




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' Mysterious Moose Mountain ' - 1:35n2 - pt.II
http://www.freerails.com/view_topic.php?id=7318&forum_id=17&page=1

' M:R:W Motor Speedway !!! ' - 1:32 Slotcar Racing Layout
http://www.slotforum.com/forums/index.php?showtopic=59295&st=0&a
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 Posted: Tue May 18th, 2021 04:56 pm
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Reg H
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I'm back!!!!!

What a journey. 
The remodel is essentially finished (have to move the furniture back in)
and the shop is back to being a machine shop.

Trying to use my machine shop as a wood shop was not a happy experience. 
It is really too small for ambitious woodworking projects,
and the sawdust from the fine cut saw blades covers, and gets into, everything.

But here we are, back in business.










In the process of doing some tasks that needed doing,
my old, but sturdy, Orion hacksaw packed it in. 

I like having two saws, one with the 24 TPI blade and one with 32 TPI. 
So I will be on a search for a new saw. 

I will keep you informed on the results of my search. 
My experience is that finding good, sturdy hacksaws is difficult. 

We shall see.

Work on the Shay we commence forthwith.

Reg




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 Posted: Tue May 18th, 2021 09:42 pm
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Si.
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Hi Reg  :wave:


Yeah ... Wood dust is a total pain.  :f:

I try & do all that stuff outside if I can.


I'm on hacksaw No.4 in my lifetime of pain !!!!  ;)

& happy at long last !  :bg:


No.1 - Old round wooden handle job ... AAAARRRRGGGGHHHH !!!!

No.2 - Forgot the brand, Handle designed by 'Ergons' ... AAARRRGGGHHH !!!

No.3 - Roebuck, Another 'Design Student Job' probably ... AARRGGHH !!

No.4 - 'Bahco 317', Those darn clever & infinitely sensible Swedes ... End of story.





It aint even expensive & Amazon have them here in the UK, so quick & easy to get.

Changing blades is very EASY, balance is GREAT, handle angle & design EXCELLENT !


:java: :brill: :dt:


Si.




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' Mysterious Moose Mountain ' - 1:35n2 - pt.II
http://www.freerails.com/view_topic.php?id=7318&forum_id=17&page=1

' M:R:W Motor Speedway !!! ' - 1:32 Slotcar Racing Layout
http://www.slotforum.com/forums/index.php?showtopic=59295&st=0&a
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 Posted: Fri May 21st, 2021 05:46 pm
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Reg H
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I finally got some shop time. 

Between the remodel, and my wife's health challenges,
shop time has been very limited.

As noted earlier, I got some shop time dedicated to clean up from the remodel project.
This time, I actually got to work on the Shay. 

There were several small items that needed doing in order to reach a major milestone.
The end sills are complete!!!!










You may note that the hole with the broken tap is still lacking a bolt head. 
I will address that issue during final, final, final assembly. 

There may yet be reason to disassemble this end sill in order to do some drilling.
Notably, the mounting holes for the braces that run from the frame rails to the end sill.










There will be nuts on the ends of the bolts passing through the frame rail mounting brackets. 
I have some Nylocs for these locations. 

I really don't want frame rail mounting bolts coming loose. 
But they are fussy to install (2.5mm bolts/nuts) and will wait until final assembly to install.





Yes.  I know the one poling pocket is slightly crooked. 
These are held in place by a single screw. 

Kozo is saying that paint will hold these in alignment. 
I think, at final assembly, that I will put a drop of Loctite under each one. 


I keep talking about "final assembly". 
In a project like this, where almost all parts are being fabricated from raw stock,
there is a great deal of fitting and adjusting. 
Nothing is finally assembled until all the parts have been fabricated and test fit.  

Actually, I am planning two "final assemblies". 
The first will ensure everything fits and operates as it should.
 
Then major sub assemblies will part company for paint. 
Once painted the final, final assembly will take place. 
That is a long way down the road.  I am hoping five years.


The next step is the bolsters. 
I should be able to machine, drill and tap those parts in one evening.  Maybe. 
After I fabricate the drilling jig.  Which will probably take an evening.

Reg




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